Manufacture of splice bars



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MANUFACTURE OF SPLICE BARS Nov. 3, 1959 17 Sheets-Sheet 6 Filed May 3, 1957 Nov. 3, 19-59 c. F. HAUTAU 2,911,117

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MANUFACTURE OF SPLICE BARS Filed May 3, 1957 17 Sheets-Sheet 8 Nov. 3, 1959 c. F. HAUTAU MANUFACTURE oF SPLICE BARS 17 Sheetssheet 9 Filed May 5' 1957 ;Y 5 -I Ilf: 1 mm.

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MANUFACTURE OF SPLICE BARS 1'7 Sheets-Sheet 10 Filed May 3, 1957 WWF- Nov. 3, 1959 c. F. HAUTAU MANUFACTURE oF SPLICE BARS 17 Sheeis-Sheet 11 Filed May 3, 1957 c. F. HAUTAU MANUFACTURE oF SPLICE BARS Nov. 3, 195g H 17 Sheet5sheet 12 Nov. 3, 1959 c. F. HAUTAU 2,911,117

MANUFACTURE 0F SPLICE BARS Filed May 3, 1957 17 Sheets-Sheet 15 Nov. 3, 1959 l l "lum C. F. HAUTAU MANUFACTURE OF' SPLICE B ARS Filed May 3, 1957 W HM han ' 1'7 sheets-sheet 14 v Nov. 3, 1959 c. F. HAUTAU 2,911,117

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MANUFACTURE OF SPLICE BARS Filed May 3, 1957 17 Sheets-Sheet 1'7 United States Patent O MANUFACTURE F SPLICE BARS Charles F. Hautau, Huntington Woods, Mich., assignor to Inland Steel Company, a corporation of Delaware Application May s, 1957, serial No. 656,913 v z Claims. (Cl. 214-18) This invention relates to the manufacture of splice bars such as are used to connect the ends of railroad rails. Heretofore such bars were made by manually moving or carrying splice bar stock from one machine to another, such as the shear, heating furnaces, a series of presses, reheating furnace, and quench tank. Such a procedure required a great deal of floor space in the manufacturing area and many operators, i.e., much manual labor. All of this ran the cost of producing splice bars up to quite a high price.

According to this invention automation to a practical extent is achieved. The only manual operation is that of initially .loading the splice bar stock upon storage skids at the start of the line and initially feeding the long bars into the beginning of the processing line. In general, the load of splice bar stock, i.e., hot rolled sections, as it is rolled and received from the mill in lengths from to 40 feet and sometimes as long as 60 feetis placed on the stock rack by cranes. Thereafter each bar is manually dragged onto a roller table from which the bar stock is fed automatically into the shear by a carriage which automatically starts the shear to cut the stock into splice bar lengths, while the carriage moves back to take a new hold for the next feeding move. After shearing, the cut bars are swept automatically into and through the heating furnace by two parallel chain conveyors which receive alternate bars from the shear. As the bars leave the furnace upon the two chains they are again swept automatically land alternately in a single line into a plurality of catapults which project the bars individually and progressively into and through three presses. As the bars leave the last press they are again automatically swept alternately upon a pair of parallel chain conveyors and carried through a reheating furnace. As the bars leave the reheating furnace they are discharged onto a conveyor which carries them into a quench tank. From the quench tank the bars are discharged onto an inspection conveyor, which in turn discharges the bars into a loading box.

A better understanding of this invention will be had from the following description when read in connection with the drawings in which:

Fig. 1 is a schematic plan view illustrating the layout and operation of the complete apparatus;

Fig. 2 is a schematic side elevation showing the bar of stock in position after its only manual movement and gripped by the rock and shear clamps and the shear ICC performing its cropping operation while the carriage returns for another grip;

Fig. 7 is a similar View showing rack and shear clamps open and the bar of stock being pushed to its limiting stop by the carriage justvprior to automatic shearing of a splice bar length; I

Fig. 8 is a similar view showing the -bar of stock, again clamped by the rack and shear clamps, and being sheared and the splice bar dropped upon a live conveyor while the shear carriage returns vfor, additional stock;

Fig. 9 is a similar view showingv the bar being carried to the furnace charging equipment;

Fig. 10 is a schematic plan .view of the same;

Fig. 11 is a similar plan view showing how the bars are swept by the furnace charging mechanism into two vthe bar from the rst press toward the second press;

Fig. 19 is a similar view illustrating the discharge from the third press toward the reheating furnace. The same operating cycle is repeated at all three presses.

Fig. 20 is a schematic plan view of the same;

Fig. 21 is a fragmentary schematic side elevation showing the delivery of the bars from the reheating furnace conveyor to the live table for delivery to the oil quench;

Fig. 22`is a similar View showing delivery from the live table to the oil quench;

Fig.`23 is a perspective view of the stock pile and feeding table showing the first or rack clamp and end of the shear feeding carriage;

Fig. 24 is a perspective View of the iirst or rack clamp and feeding carriage as viewed from the rear of the line; l 1

Fig. 25 is a perspective view of the feeding carriage` and its mounting as Viewed from the front or operators side of the line;

Fig. 26 is a perspective View from a different angle of the operating carriage and rack clamping mechanism as viewed from'the'operators side vof the line;

-F-igf27 is a perspective View of the shear clamp holddown and illustrates the cropping operation as well as the power driven take olf rolls and Waste chute;

Fig. 28 is a perspective view from a shallow angle illustrating the furnace charging or feeding mechanism v adjacent the front of the iirst, or heating furnace, as

viewed from the operators side of the line;

Figure 29 is a perspective view from a high angle further illustrating the mechanism as shown in Fig. 28 and bringing out in more detail the magazine feeding sections;

Fig. 30 is a perspective view from the discharge end of the iirst, or heating furnace, and showing the dis' charging or delivery mechanism, sweep arm, table, and furnace catapult;

Fig. 31 is a perspective view of the delivery end of the heating furnace and transfer mechanism ltaken from a shallower angle and showing the bar as being in line with the throwing mechanism of the furnace catapult; 4

Fig. 32 is a perspective view from the operators vside of the line showing the shock absorbing mechanism and catapult mechanism in connection with the second press,

it being understood that these mechanisms are similar at' each press;

Fig, 33 is a perspective,Viewv similar to that shown in Fig. 32 but taken from the opposite end and angle, also viewed from the operators side of the line;

Fig. 34 is a perspective view from a high angle of the transfer `and charging or feeding mechanism in connection with the second, or reheating furnace, as seen from the operators side of the line;

Fig. 35 is a perspective view similar to Fig. 34 but from a lower angle and showing the sweepiarm in `a different position and the rapid feeding mechanism; and

Fig. 36 is a perspective View from the operators side of the line of the discharge end of the reheating furnace showing the conveyor rolls and tipping table for immersing the finished bars in the oil quench tank.

Referring now to the drawings, the operation and structure will be described simultaneously, starting with the bar stock. The splice bar stock which is normally in sections 25 to 40 feet long, although sometimes as long as 60 feet, is placed on the stock rack ll, shown in Figs. l and 23, by an overhead mill crane (not shown).

Each piece of barstock `10 is manually pulled from the loading skids 12 onto aroller table 13, one roller =1f4 of which is shown in Fig. 23, andanother of which is shown in Fig. 24, and also being shown schematically in Figs. l through 8. Each piece of bar stock 10 is manipulated so that the head end of the bar drop into then open jaws "15 of rack clamp '16, hydraulically operated by cylinders 17, shown in the same figures and located at the front end of the roller table and directly in line with the shear and the shear feeding mechanism later described. The front portion of the bar 10 projects through the clamp i6 which is then closed by the operator to hold the bar in position to be engaged by the shear feeding mechanism.

Shear feeder and shear The shear feeding mechanism comprises a reciprocating carriage 20, illustrated in Figs. 24, 25, 26, and 27, and schematically in Figs. l through 8, and consists of an I-beam-like member 21 (Fig. 25) provided with flanged wheel-s 22 which travel on horizontal rails 23 upon a bed, securely fastened to the oor. -I-bearn 21 carries spaced pneumatic clamps 24, operated by Vpneumatic cylinders 25, for gripping the bar. The carriage is caused to travel upon rails 23 by a hydraulic cylinder 26 (Fig. 25), Adjustable limit switches 27 determine the travel of the carriage and, accordingly, the length of the splice bar being sheared, inasmuch as the travel of the carriage determines the length of stock 10 fed to the shear 30, as determined by customers specifications. The shear may be any suitable shear, such as a 900 ton capacity United Engineering Foundry Company shear with blades shaped to iit the bar sections. Obviously, the two clamps on the carriage could be manually operated.

The feedercarriage is in the forward position, that is, a

position nearest the shear, when the bar stock is pulled from the stock pile onto the roller table and is gripped by theraok clamp. The carriage is then moved nearwardly, that is, away from the shear, with the carriage clamps open to permit entry of the head of the bar, which f is projecting through the rack clamp. As the carriage` reaches its predetermined rear position, it actuates one limit switch 27 to stop movement of the carriage and to close .the carriage clamps by well known connections, foly lowed by opening of the rack clamps shortly thereafter.

The carri-age also trips a pressure switch or shear clamp control (not shown) to thereafter start forward movement of the carriage toward the shear, pulling the bar stock with it. These movements are illustrated progressively in Figs. 2 and 3. As the carriage moves toward the shear and reaches a predetermined position, it rengages the forward limit switch 27 which stops the movement of the carriage at which point the bar is iny the shear, where it is gripped by the shear clamp 31, operated by a cylinder 32, and also by the rack clamp 1'5. At this point, the carriage clamps are opened and the carriage travels rearwardly again, under control of another pressure Vswitch (not shown) on the carriage clamps, while the shear performs the first cutting or cropping of the end portion of the bar (Fig. 27); the

cropped end dropping down a waste chute 33. Ordinarily,

the bar will project sutlciently ahead of the carriage, as is shown in Figs. 2 and 3; however, if the bar has not been accurately placed, the clamps on the carriage are released and the carriage is returned rearwardly toward the rack clamp for additional movement of the bar.

The carriage 20 on its next forward movement, caused by engagement of the pressure stop, Vcarries the bar 10 forward until its head end touches the customary adjustable gauge stop '35, indicated in Figs. 2 through 8;

the position referred to being shown in Fig. 7. At this point the carriage clamps are again released, the shear and rack clamps closed, and the shear is tripped, as is customary under control of gauge 3*5.' While the shear is cutting a splicebar rla of the correct length to bev processed, the carriage has engaged the forward limit switch 27 and the appropriate pressure switch and is returning to repeat the feeding and shearing operation continuously for the entire length of the loaded bar stock."

Either or both, and preferably the latter, of the shear and rack clamps are used to hold the bar in position while the carriage is moved automatically with its clamps open and while the shearing takes place. Automatically the carriage clamps are closed when the carriage reaches its rear position and during the return forward movement of the carriage and stock while the shear and rack clamps are open.

Furnace feeder or charger When a. splice bar :lila of the correct length has been sheared it drops to a driven roller conveyor 40 of any well known construction, shown schematically in Figs. l0 and ll, and partially in Fig. 27, which conveyor moves the cut or sheared bars 10a from the shear 30 toward the heating furnace feeder.

As the carriage moves forward toward the shear to make the last cut on the bar of stock an auxiliary section 42 of idle feed rollers 43, shown more fully in Fig. 27, overlying and interspersed between the power driven feed rollers 40, is raised by any suitable manual, hydraulic, or pneumatic means under manual vcontrol (not shown) to support the leading or front of bar 10, which would otherwise drop, and thus support the bar to insure a square cut by the shear on the nal length or spice bar 10a. After the last cut the auxiliary section of rollers is lowered and the sheared bar 10a is fed forward by the power driven rollers 4i) until the leading end of the sheared splice strikes a spring loaded cushion stop 44, shown in Figs. 28 and 29.

This position of the bar lila at this point is shown schematically in Fig. 7. As the sheared bar 10a travels toward the cushion stop, the trailing end passes and clears a counter-balanced adjustable gate 45, shown in Fig. 9, which then drops behind the trailing end of the bar and serves vas a rear end stop for the sheared bar, which is then located between the stop 44 andthe gate 45, in position to be engaged by the furnace charging mechanism, as indicated diagrammatically in Fig. 9 and shown more fully in Figs. .28 and 29. The adjustable cushion stop 44 is positioned over the pivotal point of a quadrantlike sweep arm 50, positioned over a table 52 having wear strips 53, upon which the sheared bars lila are fed by the power driven rollers 40, vas diagrammatically shown in Figs. 9, l0, and 1l, and more fully in Figs. 28 and 29.

Sweep arm 50 is Lpositioned with its pivot at the longitudinal center line of the furnace and at the entry end (Figs. 28 and 29) of two pairs of parallel conveyor chains 54. These chains extend through the furnace and travel over sprockets 56 (Fig. 30) adjacent the entry of the furnace and driven by any suitable means, such as an electric motor and suitable gear reducer (not shown) on the sprocket shafts at the discharge end of the furnace.,

and over idler take-.up wheels 7 (Fig. l28) at the entry end of the furnace. Each chain carries vertical heat-resistant bar supporting links 58. '-ihe power driven Afeed rollers 40 deliver the sheared bars v10a longitudinally, .that is, lengthwise in a direction parallel to .their longitudinal axes, to the table 52 i `front ofthe sweep Varm `50, which turns the bars broadside, i.e., .through 90, as .will `now be described. v u

When bar a strikes the spring cushion stop ;44..1the latter actuates limit switch 46 (Fig. 28) which causes the sweep arm to be actuated, i.e., -swung through a `90 arc. The arm-engages the sheared bar 10a, as shown diagrammatically in Figs. 9 and y10and structurally in Fig. 28:and moves the sheared bar transversely, i.e., bodily, over the wear strip 53 on the table 5,2, positioning the bar broadside over the entering end of one pair of conveyor chains54 and forward of one pair .of a Aseries of pairs of pivoted d ogs 60 on carriage bars62 (Fig. 29).V After the sweep arm makes this movement to the position shown in Fig. 11, a second bar 10a is fed over vtable 52 by rollers 40 into position in front of the other |face o r edge ofrarm 50, and the sweep arm reverses its movement andbodily moves the second bar transversely to present Vit broadside, rather than longitudinally, to a position over the entering end of the second pair of parallel conveyorchains and in front of one pair of asecond series of pairs of pivoted dogs 60, associated with the latter chains.v These dogs swing about their pivots and pass l.under -the barsiand serve to prevent any rearward motion-of thesheared bars. This operation of the sweep arm continues, that is, `alternate -bars are swept to alternate pairs of conveyor chains into what may be termed two .magazine areas'between the shear and the furnace, that is, one on )each :side ofthe furnace. These areas tprovide a thank of'bars for .continuous supply to the conveyor chains. Thisserves the dual purpose4 of maintainingcontinuous operation through the furnace in the event of any delay in the :feeding or shearing operation .and also V permits accurate placement of the bars onto the carrier blades or supporting links 58 of the furnace chains or conveyors.y

The sheared bars .in each magazine-are moved forward toward the furnace .by the counter-balanced dogs V,6,0 on bars 62 which bars are reciprocated by air cylinders v-64V. (Figs. 9, l0, 1l, and 29.) The movement.of,cylinders-64 is under control of a limit switch 66 (Fig. 29), engaged by the splice bars 10a in timed sequence with =the vfurnace chains, so that the bars 10a are deposited on the carrier blades at uniformly timed inter-vals.

Heating furnace carrier blades or links projectthroughthe hearth forsup-V port of the bars. As previously stated,-any suitable means, such as an electric motor (not shown), maybelused yfor vdriving theA sprockets. Accordingly, the sheared bars pass through the heating oven broadside, so to speak, ca'rried on the two parallel conveyor chains, being placed thereonby the sweep arm fromthe continuous longitudinal line of sheared bars, turned bythe sweep'armsand stacked in the magazine sections between the gate and forward stop.

Furnace unloading mechanism j The furnace unloading mechanism Iperforms exactly the reverse function of the furnace charging mechanism. That is, as the sheared heated bars 10a comeout of the discharge, or .hot end of the furnace in parallel streams,

the bars must .bereturned to a single line of shearedfbars', progressing in a longitudinal direction, rather than two lines broadside, for feeding into the ,plurality ofpresses for processing while hot. At the final end of their travel just outsideof the furnace, the discharge ends ofthe conveyors 54 move the KAbars 10a on to wearstrips 82, mounted on a table S4, 'where .they are engaged by a second sweep arm S6, which is also a 90 arcuate segment, movable 90"- about a pivot on `the center line of the Yfurnacel In this case, the sweep -arrn 86, instead of pushing the bars .as in thecase of therfurnace charging quadrant, pulls the bars .through a 90 arc, .that is, rotates them froma broadside position to a longitudinal position. To accomplish this, each face or edge of the sweep arm isA provided with a pivoted bifurcated gate .88 upon the ends of a pair of lingers 90. Gates 88 permit the bars, traveling on the furnace chains, to move -under .the gates which then pull the bars around alternately Vfrom the chains. The sweep arm is actuated by any suitable means, such as air cylinders 91.(Figs. 14 land 3l), under control of limit switch 92 (Fig. 31), tripped by .the bar in its final steps of forward movement 0E the furnace chains and under the gates.

' Sweep arm 50 is operated by a similar mechanism (not shown). .Operationof arm 86 is shown diagrammatically lin Figs. .12V and 13 .which show how alternate bars are ,engaged'from the two'parallel conveyor chains and swung through an arc of 90 to place them imposition for further movement in a guide trough 93 (Fig. 30) toward the presses. The structure involved is shown more p-articularly in Figs. 30 and 31. n -v At the pivotal point of the -furnace discharge or unloading .sweep arm .there is an air operated catapult 94.

As the sweepA arm completes its movement and places the bar in position on `the center line of the furnace, the arm actuates one' of two limit switches 95 which causes operation ,of the catapult 94. The catapult ,thus operated strikes the end of the bar, firing it along trough 93 and into the first press of three presses, as shown diagrammatically iny Figs. 14 and 15, and structurally in Figs. 32 and 33 in Vconnection, with the second press 10061. This mechanism is similar as to all three presses.

Press loading and unloading -The three presses are of any -well known vmakesucn as The Long and Allstatter Co. and in the illustrated embodiment of this invention are of 1150 tons capacity. They have a speed of about 8 strokes per minute, are synchronized and come to `a stop at top dead center.

The sheared and heated bar 10a is moved along trough 93 by catapult 94 until bar 10a Strikes the plunger 102. ofa cushioning cylinder 104 (Fig. 15) at the discharge side of the press. At this time the plunger and cylinder are in their lowered position, i.e., in the trough in the path of the bar 10a with the plunger in its central or mid position. The plunger 1102 is preferablymade sectional so as to be adjustable to accommodate different length splice bars. In so moving, the bar passes over a lowered or retracted. press catapult 106 vwhich has been lowered below trough 93 by an air cylinder 10'7 (Figs. 14 and 18). Plunger 102 `is moved intol cylinder 104 by the bar and actuates `the rst of three limit switches v108. This causes the catapult 106 to rise on the entry side of the press` (Fig. 16), followed by return movement of plunger 102 which moves the sheared heated bar backward, i.e., centers the bar between the catapult 106 and plunger 102 directly beneath the press 100a (Figs. 16, 32, and 33).l return movement of the cushion plunger 102 the second limit `switch 108 is actuated, which starts the press which, in the case of' the first press, straightens and slots they switch 109 which causes the plunger to return to its mid Upon 

